Prosthetic joint with dynamic torque compensator

ABSTRACT

A constant torque joint utilizes joint elements extending respectively between brace attachments for use in an anatomical brace. The brace has a range of motion dependent upon the particular application and in one embodiment from about 65° to about 215° with an included angle of motion of approximately 150°. A constant torque in the joint is provided by a spring-loaded cable wherein a cam driven cable anchor pin is utilized to compensate for variations in the spring cable joint system to produce a constant torque within the joint throughout the full range of motion of the joint.

This is a division of application Ser. No. 08/355,605, filed Dec. 14,1994, now U.S. Pat. No. 5,575,764.

BACKGROUND OF THE INVENTION

This invention relates to mechanical prosthesis and particularly to aconstant torque joint for anatomical braces.

In the past, treatment for various muscular, skeletal or nervousconditions has included the utilization of particular anatomical braceswhich are applied to a patient's appendage and which either supportsthat appendage or which provide a rehabilitative measure of resistanceto movement of that appendage. In this way, the patient's muscular,skeletal or nervous system can be exercised and used with a view towardrehabilitation.

While a variety of different types of such braces have been provided,the currently available structures have certain inherent disadvantages.For example, while the braces may provide an adequate range of motion,they do not provide for constant resistance or torque over that range ofmotion; and thus, the maximum rehabilitative benefit of the exercise isnot realized. Even where certain springs are utilized in an effort toprovide a constant torque or resistance to motion of the joint betweentwo different parts of the brace, the vagaries of spring rates, springmanufacturing, spring materials, and system friction or other forcesimpede a result of constant torque or resistance.

Accordingly, it has been an object of this invention to provide aconstant torque joint for an anatomical brace such that a constantresistance to motion is applied by the joint connecting two differentportions of the brace movable with respect to each other throughout theentire range of movement thereof.

It has been another objective of the invention to provide an anatomicalbrace having a constant torque throughout its full range of motion.

It has been another objective of the invention to provide a compensatorfor accommodating system foibles toward the goal of producing a constanttorque or constant resistance to the joint for use in rehabilitation.

It has been another objective of the invention to provide a constanttorque coupling.

SUMMARY OF THE INVENTION

To these ends, a preferred embodiment of the invention contemplates theutilization of a spring-powered torque-producing cable combined with adynamic torque compensator for minimizing torque variations of the jointthroughout its full range of movement. In particular, a preferredembodiment of the invention includes a torque-producing cable connectedto a compression spring, wherein another end of the cable is threadedabout a variety of pins associated with the pivot point of the jointsuch that a constant torque is produced by the joint by virtue of thecable wrapping about a center or pivot pin and anchored by a freefloating anchor pin. The anchor pin is cam driven to compensate forspring and other system variations so that the end result is a constanttorque or constant resistance joint where a constant torque is providedthroughout the full range of motion.

In a preferred embodiment, for example for use in connection with anelbow, the range of motion of the joint is approximately through 150°beginning at a 65° separation of the two brace extensions andterminating at about 215° separation thereof. It will be appreciatedthat other ranges of motion are available with the joint of thisinvention for different body joints. The results are obtained throughthe utilization of an arcuate slot accommodating a pulley pin andthrough the utilization of a floating anchor pin travelling within aradial slot and being driven by means of an arcuately shaped eccentriccam. The configuration of the arcuately shaped eccentric cam is afunction of the non-linearity of the spring response and thecompensation for it as to be described herein. As the joint movesthrough its various positions, the resulting torque, or resistance tomotion is maintained at a constant level as the cable is wrapped aboutthe pivot pin and a moment arm of the joint varies as the anchor pintranslates within the radial slot.

The invention produces a joint which can be used, for example, in anelbow brace for accommodating motion from a fully open position,accommodating an angular orientation of about 215° between theextensions of the brace on each side of the joint to a fully closedposition of about 65° between those two members. The range of motion ofthe joint accommodates the typical full range of an anticipated elbowrotation and provides a constant torque or resistance against motionthroughout that entire range. Such a constant torque joint is provided,while at the same time maintaining the joint in a very small package sothat the brace itself can be relatively small and easily used.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages and objectives of the invention will become more readilyapparent from the following description of the details of a preferredembodiment of the invention and from the drawings in which:

FIG. 1 is a top plan view of a joint with a dynamic torque compensatoraccording to this invention;

FIG. 2 is a side cross-sectional view taken along line 2--2 of FIG. 1;

FIG. 3 is a side cross-sectional view taken along line 3--3 of FIG. 1;

FIG. 4 is an exploded perspective view of the components of a preferredembodiment of the invention; and

FIGS. 5A through 5C are top cross-sectional views of the joint with theextensions in various angular relationships relative to one another.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

A perspective view of a prosthetic joint 10 with a dynamic torquecompensator is shown in FIG. 4. The invention is described herein andshown in the drawings in a particular embodiment, as for example a jointfor use in rehabilitating an elbow joint; however, other configurationsand embodiments are possible and within the scope of the invention. Thejoint 10 includes a torque cable 12 secured at first and second ends bya collar 14, 16, respectively. A first end of the cable 12 passesthrough a hole 18 in a fixed stop plate 20, the center of a helicalcompression spring 22, and a hole 24 in a movable abutment plate 26. Thecollar 14 is juxtapositioned to a face of the movable abutment plate 26opposite from the spring 22. The cable 12 passes through the spring 22and stop plate 20 and through a hole 28 within a side wall of agenerally circular bushing 30. After entering the bushing 30 through thehole 28, the cable 12 wraps around a face of a tangent pin 32 and thenaround an opposite face of a center pivot pin 34. The cable 12 thenpasses around a traveling pulley pin 36 and passes through a hole 38 inan anchor pin 40. The collar 16 is juxtapositioned on an opposite sideof the anchor pin 40 to secure the cable 12 thereto. The cable 12 isshown as having a first end terminating at the movable abutment 26 and asecond end terminating at the anchor pin 40. However, it will beappreciated that both ends of the cable 12 could be secured to themovable abutment 26 with the cable 12 folded back on itself and eachportion thereof passing through the spring 22 and the bushing hole 28,around the respective pins as indicated and looped around the anchor pin40 thereby avoiding the need for the collar 16 securing an end of thecable 12 to the anchor pin 40. Routing the cable 12 in this manneralleviates the need for the hole 38 in the anchor pin 40, therebyproviding a more structurally sound anchor pin 40 which is less prone tofailure. Likewise, the cable 12 is of a double thickness over most ofits length, thereby providing a stronger cable within the joint 10 ofthis invention.

The cable 12 and bushing 30 are sandwiched between an upper and a lowergenerally planar moving plate 42a, 42b, respectively, in a presentlypreferred embodiment of the invention. The upper and lower moving plates42a, 42b are identically configured and aligned and each include agenerally circular portion 44 and a generally rectangular arm 46extending therefrom. The upper and lower moving plates 42a, 42b and thebushing 30, when assembled, are fixed relative to each other by tabs 48which project from a perimeter edge of the circular portion 44 of eachmoving plate 42a, 42b. The tabs 48 are seated within notches 50 in theupper and lower edges of the bushing 30. Similarly, enlarged notches 52are provided on the upper and lower edges of the bushing 30 toaccommodate the arms 46 projecting from the circular portions 44 of theupper and lower moving plates 42a, 42b when the bushing 30 is sandwichedtherebetween.

The moving plates 42a, 42b each include a pivot pin aperture 54centrally located within the circular portion 44 thereof and along apivot axis 56 of the joint 10. The moving plates 42a, 42b also include atangent pin aperture 58 spaced from the pivot pin aperture 54. The pivotpin 34 and tangent pin 32 extend through the pivot pin aperture 54 andtangent pin aperture 58, respectively, to fix the position of the pinsrelative to the moving plates. The tangent pin 32 and aperture 58 arelocated to maintain the cable 12 in contact with the pivot pin 34 as thejoint 10 is pivoted. In a preferred embodiment, the cable 12 between thetangent pin 32 and the stop 20 is positioned along a centerline 60 ofthe moving plate arms 46.

The moving plates 42a, 42b also include an arcuate cam slot 62 proximatethe perimeter of the generally circular portion 44. In a presentlypreferred embodiment, the arcuate cam slots 62 in the upper and lowermoving plates 42a, 42b capture the pulley pin 36 therein and enable thepulley pin 36 to pass through an arc of approximately 150°. The arcuatecam slots 62 begin at approximately the centerline 60 of the arm 46 ineach of the moving plates 42a, 42b and extend proximate a perimeter edgeof the circular portion 44 through an angle of about 150°. The arcuatecam slot 62 is a constant distance away from the pivot axis 56 of thejoint 10 which extends through the pivot pin 34 and the pivot pinaperture 54.

The upper and lower moving plates 42a, 42b each also include aneccentric cam slot 64 which captures the anchor pin 40 therein. Theeccentric cam slot 64 in a presently preferred embodiment enables theanchor pin 40 to travel through an arc of approximately 150°. Theeccentric cam slot 64 is eccentrically positioned relative to the pivotaxis 56 of the joint 10 so that one end of the eccentric cam slot ismore closely spaced relative to the pivot axis 56 than a second endthereof. Therefore, as the anchor pin 40 travels within the eccentriccam slot 64, the separation between the pivot axis 56 and the anchor pin40 increases or decreases depending on the direction of travel.

A terminal end of each arm 46 of the moving plates 42a, 42b has a ledge66 on each side edge thereof. Each ledge 66 is configured to accommodatea side plate 68 positioned perpendicular to the arm 46, the stop 20 andmoving abutment 26 as shown in FIG. 1. With the upper and lower movingplates 42a, 42b sandwiched around the bushing 30, the side plates 68 areseated within the ledges 66 on the arms 46 of the moving plates 42a, 42band the spring 22, stop 20, and abutment 26 are positioned between theside plates 68 (FIG. 1).

Similarly configured upper and lower stationary plates 70a, 70b,respectively, are juxtapositioned to the upper and lower moving plates,42a, 42b, respectively, as shown in FIGS. 2-4. Each stationary plate70a, 70b also includes a generally circular portion 72 and arectangularly shaped arm 74 extending from the perimeter thereof. Aterminal end of each arm 74 includes ledges 76 on opposite side edgesthereof. In a preferred embodiment of the invention, the diameter of thecircular portions of the stationary plates 70a, 70b and the movingplates 42a, 42b are equal. The stationary plates 70a, 70b include pivotpin apertures 54 centrally located within the circular portions 72 andcapturing the pivot pin 34 along the pivot axis 56 of the joint 10. Theupper and lower stationary plates 70a, 70b also include a radial slot 78capturing the anchor pin 40 and permitting the anchor pin 40 to travelalong a radius of the circular portion 72 projecting from the pivot axis56 and pivot pin aperture 54. The radial slot 78 is aligned in apreferred embodiment along a centerline 80 of the arm 74 which passesthrough the pivot pin aperture 54. However, the radial slot 78 could bein a different location on the stationary plates 70a, 70b within thescope of this invention. The movement of the anchor pin 40 within theradial slot 78 corresponds to the changing length of the moment armwithin the joint 10. The changing moment arm length compensates for thenon-linearity of the spring rate to provide a constant torque joint 10as described in detail later herein.

A pulley pin aperture 82 is positioned proximate a perimeter edge of thecircular portion 72 of each stationary plate 70a, 70b. The pulley pinaperture 82 is positioned approximately 30° from the centerline 80 ofthe arm 74.

An upper and a lower circular cap plate 84a, 84b, respectively, arepositioned on the top and bottom surfaces of the joint 10, respectively.Each cap plate 84a, 84b includes a pivot pin aperture 54 centrallylocated therein along the pivot axis 56 of the joint 10. The upper andlower cap plates 84a, 84b sandwich the stationary plates 70a, 70b,moving plates 42a, 42b, and bushing 30 therebetween. It will beappreciated by one of ordinary skill in the art that the components ofthe joint according to this invention can be secured into an operationalconfiguration by an appropriate fastener such as a bolt (not shown)passing through the pivot pin and pivot axis to maintain the joint in anassembled configuration.

One of ordinary skill in the art will realize that the pivot pinaperture 54, tangent pin aperture 58 and pulley pin aperture 82 eachpermit rotation of the respective pins inserted therein while fixing thepositional relationship of the pins to the respective plates. Similarly,the eccentric cam slot 64, arcuate cam slot 62 and radial slots 78 eachpermit the respective pins inserted therein to rotate and/or translaterelative to the respective plates.

The eccentric cam slot 64 has a first end aligned on the centerline 80of the stationary arm 74 and extends approximately 150°, in a specificpresently preferred embodiment, thereby having a portion adjacent to aportion of the arcuate slot 62 without interfering therewith. As can beseen in FIGS. 1-3, the cable 12 enters the joint 10 through the bushinghole 28 and passes behind the tangent pin 32 and in front of the pivotpin 34 and is then fished behind and around the traveling pulley pin 36and secured to the anchor pin 40. The position of the tangent pin 32 isfixed relative to the pivot pin 34 to maintain the cable 12 in contactwith the pivot pin 34 as the stationary and moving arms 74, 46,respectively, are pivoted relative to each other. The arms 46 of themoving plates combine to form an extension of the joint 10 which can beeasily incorporated into a rehabilitative-exercise tool or other systemapplication. Similarly, the arms 74 of the stationary plates combine toform another extension of the joint.

The angular relationship between the center pin 34 and the pulley pin 36does not change with respect to the stationary arms 70a, 70b duringoperation of the joint 10. In addition, the anchor pin 40 and the centerpin 34 remain aligned on the centerline 80 of the stationary arms 70a,70b during movement of the joint 10.

In operation, the joint 10 of the present invention provides a constanttorque or resistance to movement of the arms 46 of the moving plateswith respect to the arms 74 of the stationary plates. The length of thecable 12 and moment arm in the joint are advantageously adjusted by theinteraction of the pins and slots as the extensions are moved angularlyrelative to one another. The adjustment of the moment arm lengthcompensates for the variations in the spring rate as the spring 22 iscompressed from an expanded to a compact configuration.

In a preferred embodiment of the invention, the range of movement of themoving arms 46 relative to the stationary arms 74 is approximately 150°beginning at a closed position of approximately 65° angular separation(FIG. 5C) between the extensions and terminating at about 215° angularseparation in an open position. In the open position, as shown in FIG.5A, the extensions are spaced angularly-approximately 215° apart. Theanchor pin 40 is positioned within the eccentric cam slot 64 at one endthereof on the centerline 80 of the stationary arms 74. In addition, theanchor pin 40 is positioned within the radial slot 78 at the maximumdistance away from the pivot pin 34 and pivot axis 56 thereby providinga longer moment arm in the joint. The pulley pin 36 is positionedapproximately 150° from the centerline 60 of the moving arms 46 at oneend of the arcuate cam slot 62. In the open position, the spring 22 isin its most relaxed configuration with the abutment plate 26 beingspaced a maximum distance away from the stop 20.

As the extensions of the joint 10 are pivoted from the open positiontoward the closed position, the length of the cable 12 extending fromthe joint will be shortened thereby compressing the spring 22 andshortening the distance between the stop 20 and the movable abutment 26.As shown in FIG. 5B, as the moving arms 46 are pivoted toward thestationary arms 74 and away from the open position, the pulley pin 36travels along the arcuate slot 62 toward the centerline 60 of the movingarms 46. The anchor pin 40 travels along the eccentric cam slot 64 andthe radial slot 78 and moves closer to the pivot pin 34 shortening themoment arm. The pulley pin 36 maintains a constant spacing from thepivot axis 56 and pivot pin 34 of the joint 10 as it travels within thearcuate slot 62. As the extensions are collapsed toward the closedposition, the anchor pin 40 moves within the radial 78 and eccentricslots 64 toward the pivot axis 56.

The joint 10 is shown in the closed position in FIG. 5C with the anchorpin 40 at the respective ends of eccentric cam 64 and radial slots 78.The pulley pin 36 is at the end of the arcuate slot 62 proximate thecenterline 60 of the moving arms 46 in the closed position. Theseparation between the pivot and anchor pins, and consequently themoment arm, is the smallest in the closed position. As a result of theinteraction between the cable, the pins in their respective slots andapertures, and the spring, a constant torque or resistance to angularmovement is provided by the joint of this invention. The torque orresistance to movement at any angular separation of the extensions is aconstant thereby providing a useful and beneficial exercise tool for therehabilitation of injuries to human joints such as knees, elbows or thelike.

It will be appreciated that the invention provides a constant torque orconstant resistance joint 10, which has a particular useful applicationin anatomical braces, such as for the elbow. In a preferred embodimentof the invention, the constant torque is produced in part by thewrapping of the torque cable 12 about the pivot pin 34 within the joint10 and the compensation provided by the movable anchor pin 40. Thelength of the cable 12 is preferentially adjusted by means of thefloating anchor pin 40, so that its relative length can be varied,depending on the position of the anchor pin 40, which in itself is afunction of the range of motion of the joint 10 so that the vagaries ofthe spring 22 powering the cable 12 and of the remainder of the systemcan be taken into account and eliminated to result in a constant torquejoint 10. It should also be appreciated that the constant torque orconstant resistance joint 10 may have application in other fields otherthan anatomical braces for skeletal, muscular, or nervous systemrehabilitation devices.

Design Process for Constant Torque Compensation in a Joint

The design process for a joint according to this invention which has aconstant torque compensator is initially dependent upon a number offactors which are typically provided by the physical therapist, devicemanufacturer, rehabilitation specialist, or the like. In particular, therange of motion of a device according to this invention is dependentupon the particular human joint or exercise program for which it will beused. For example, the rehabilitation of an elbow joint may require aconstant torque over a range of 150° between 65° and 215°; whereas aknee joint may require a range of only 135° between 45° and 180°.Therefore, the range of motion must be provided to the designer.

Next, the magnitude of the torque resistance that a device providesduring the exercise must be provided to the designer. For example,rehabilitation of the elbow joint might require a constant torqueresistance of 0.5 ft-lbf over the range of 150° but a knee joint mayrequire much more resistance. Furthermore, the particular distance theextension arms of the joint will be attached to the user must bedetermined. For example, each extension arm from the joint might beattached to the user's upper and lower arm 6 inches away from the elbowjoint but a different device may be attached 10 inches on either side ofthe knee. Next, these parameters must be translated to the size of thedevice, a spring design selected, the vagaries of the particular springselected determined, and the compensation for these vagaries calculatedand applied to the joint according to this invention.

The maximum spring force and minimum spring load are factors which mustbe provided in the design of the joint. The maximum spring force is thatwhich should be produced by the device with the joint in the closedposition and the minimum spring force is that which is produced atmaximum separation between joint extensions in the open position.

Another factor important for the design of a joint is the physicalconstraints of the actual device. The maximum allowable diameter andlength of the spring are factors which must be incorporated into arehabilitation exercise device while still providing the required springforce resistance over the entire range of motion.

Next, one must determine the preload on the spring to give sufficientspring force through the entire range of motion of the joint. Thediameter of the pivot-pin is then selected in order to give anappropriate wrapped cable length about the pivot pin that is within thedesired range of deflection of the spring. The cable wrap about the pincan be determined by the portion of the outer circumference of the cablewhich contacts the pin over the range of motion of the joint. The springwrap distance around the pivot pin is equal to the change in the momentarm or the distance the anchor pin travels within the radial slot.

The spring rate must then accurately be determined over the deflectionrange for this particular joint. To determine the accurate springdeflection rates over the deflection range, a statistically sufficientnumber of springs of this design must be tested. For example, therequired load for each 0.1 inches of deflection of the spring over thedeflection range is measured and plotted as a curve for this particularspring design. The plot of deflection versus pounds of force is notlinear due to the vagaries of the spring design and manufacture.

Given the spring rate curve and the radius arm lengths determined by theanchor pin at the maximum and minimum loads, a second spring rate curveis generated to compensate for the geometry of the cable extending fromthe pulley pin to the anchor at the various anchor pin locations. Theforce applied on the anchor pin in the closed position is perpendicularto the moment arm between the pivot pin and the anchor pin. However, asthe moment arm distance increases and the anchor pin moves within theradial slot away from the pivot pin, the force of the cable upon theanchor pin is no longer perpendicular to the moment arm and anonperpendicular component of the force is introduced as a result.Standard vector analysis as would be known by one of ordinary skill inthe art can be used to arrive at a compensated spring rate curve.

Through known mathematical analysis including computer aided designprograms and the like, the compensated spring rate curve is thenapproximated to give a best fit approximation with the least amount ofvariation between the plot and the compensated spring rate curve.Preferably, the appropriations of the plot should be less than themanufacturing tolerances of the joint. The resulting curve is thenmapped onto the moving plate to define the eccentric cam slot accordingto this invention. The difference between the closest and furthestpoints of the anchor pin within the eccentric slot relative to the pivotpin define the length of the radial slot.

Further theoretical vagaries can be accounted for and compensated for inthe design process of the joint according to this invention. Forexample, the cable wrap about the pulley pin is another factor whichcould be compensated for in the above described design process. Afurther factor which can be compensated for is the friction forceswithin the joint of the cable and the various pivot pins within theslots and pivot apertures of the joint. Anti-friction coatings such asteflon washers are preferably included into the manufacturing process ofthe components of a joint according to this invention.

From the above disclosure of the general principles of the presentinvention and the preceding detailed description of a preferredembodiment, those skilled in the art will readily comprehend the variousmodifications to which the present invention is susceptible. Forexample, other energy devices may be substituted for the spring in theconstant torque joint and be within the scope of this invention.Therefore, I desire to be limited only by the scope of the followingclaims and equivalents thereof.

I claim:
 1. A method of providing constant torque and resistance tomovement between two joint extensions coupled for relative angularmovement with respect to each other at a joint, said method comprisingthe steps of:coupling a cable to one end of a joint extension, the otherend of said cable being mounted relative to the other joint extension,one of the joint extensions configured to adiust a length of said cableduring angular movement of said joint extensions; applying a force toone end of said cable; producing a torque between the joint extensionsupon angular movement of the joint extensions relative to each other,said torque being in-part a function of said force applied to saidcable; and adjusting a length of said cable as a function of the angularorientation of the joint extensions with respect to each other tocompensate for vagaries of the force application to said cable andmaintain said torque as a constant as said extensions move relative toeach other.
 2. The method of claim 1 wherein said adjusting stepcomprises wrapping said cable about a plurality of pins within thejoint.
 3. The method of claim 2 further comprising:capturing selectedones of said pins within slots so that said selected pins move withinsaid slots upon relative pivotal movement of the joint extensions. 4.The method of claim 3 wherein the movement of at least one of saidselected pins varies a length of a moment arm in the joint.
 5. A methodof rehabilitating a human joint comprising the steps of:providing a pairof extensions being pivotally coupled at a joint; coupling a cable toone end of a joint extension, the other end of said cable being mountedrelative to the other ioint extension, one of the joint extensionsconfigured to adiust a length of said cable during angular movement ofsaid joint extensions; applying a force to one end of said cable;producing a torque between the joint extensions upon angular movement ofthe joint extensions relative to each other, said torque being in-part afunction of said force to said cable; adjusting a length of said cableas a function of the angular orientation of the joint extensions withrespect to each other to maintain said torque as a constant as saidextensions move relative to each other; and repeatedly moving saidextensions relative to each other with the human joint to berehabilitated.
 6. The method of claim 5 wherein said force is applied tosaid one end of said cable with a compression spring attached thereto.